Footwear with padding and midsole structures and the method of making the same

ABSTRACT

A method of manufacturing an article of footwear includes positioning an upper on a last that defines openings connected by one or more channels in the last, injecting a material through the one or more channels in the last, and forming a structure on the upper with the material.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.16/047,687, filed Jul. 27, 2018, which is incorporated herein byreference in its entirety.

BACKGROUND Field

Embodiments of the present invention relate generally to footwearcomponents, and more specifically to footwear components made from apolymeric material injected through various ports of a 3D object, suchas a last.

Background

Injection molding is used in footwear manufacturing to make variousfootwear components, such as midsoles, outsoles, and cleat plates. Inknown uses of injection molding, material is injected through in-gatesof a set of mold plates and shaped based on the style of the moldplates. These systems lack the flexibility to mold and shape footwearcomponents creatively and therefore limit manufacturing (e.g., limitedto the mold plates' shapes, limited to the material best suited for theprocess, etc.). In addition, the process is cumbersome andtime-consuming. Therefore, there is a need to improve shaping footwearcomponents in an efficient, customizable, and fast manner.

BRIEF SUMMARY

Footwear with padding and midsole structures are disclosed, as well asthe method of making such footwear components. In some embodiments, thefootwear components are made from at least one polymeric materialinjected through various ports of a 3D object, such as a last. Thefootwear components include, but are not limited to, a midsole, heelcounters, ankle and heel padding, medial and lateral supports, and otherinternal or external structures. In some embodiments, the footwearcomponents are made by injecting at least one polymeric material througha last having channels within the structure. In some embodiments, thechannels include openings from which material exits and forms thedesired footwear components. In some embodiments, the footwearcomponents are formed in and around a 3D footwear upper component, suchas a knitted sock or similar material.

In some embodiments, a method of manufacturing an article of footwearincludes positioning an upper on a last. In some embodiments, the lastdefines openings connected by one or more channels in the last. In someembodiments, a method of manufacturing an article of footwear includesinjecting a material through the one or more channels in the last andforming a structure on the upper with the material.

In some embodiments, the structure includes a midsole. In someembodiments, the structure includes upper padding. In some embodiments,the openings include an inlet at a top of the last and an outlet at abottom of the last.

In some embodiments, the method includes customizing the structure basedon data associated with a wearer. In some embodiments, customizing thestructure includes customizing a location of the structure. In someembodiments, customizing the structure includes customizing a shape ofthe structure. In some embodiments, customizing the structure includescustomizing the material of the structure. In some embodiments, themethod includes customizing the upper based on data associated with awearer.

In some embodiments, the last defines a cavity at a bottom portion ofthe last. In some embodiments, the cavity extends most of the length ofthe last and most of the width of the last. In some embodiments, formingthe structure on the upper includes forming an insole in the cavity.

In some embodiments, the last includes a pattern with at least one ofengraved features and embossed features.

In some embodiments, a method of manufacturing an article of footwearincludes positioning an upper on a last, injecting a material throughthe last, and forming upper padding and a midsole with the material in asingle, continuous process. In some embodiments, the method includesinjecting a second material through the last. In some embodiments, themethod includes using a modular attachment to shape the upper padding.In some embodiments, the method includes obtaining foot data associatedwith a wearer. In some embodiments, the method includes using the footdata associated with the wearer to customize the midsole and the upperpadding.

In some embodiments, an article of footwear includes an upper and asingle-injection midsole and padding disposed on the upper. In someembodiments, the single-injection midsole and padding is distinct fromthe upper. In some embodiments, the padding is disposed on an outside ofthe upper. In some embodiments, the padding is disposed on an inside ofthe upper. In some embodiments, the padding is customized based on footdata associated with a wearer. In some embodiments, the midsole includesmultiple materials. In some embodiments, the midsole includes amulti-density material.

In some embodiments, a last includes a body defining a channel extendingfrom an inlet opening to an outlet opening. In some embodiments, thebody of the last defines multiple channels. In some embodiments, thelast includes one or more patterns on an outer surface of the body. Insome embodiments, the patterns are embossed on the outer surface. Insome embodiments, the patterns are engraved on the outer surface. Insome embodiments, the patterns include embossed and engraved features.In some embodiments, the patterns include ridges or raised structures.In some embodiments, the patterns are disposed in one or more of theheel region, midfoot region, and forefoot region. In some embodiments,the patterns are disposed in one or more of the toe-box, vamp, quarters,or tongue region of the last.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated herein and form a partof the specification, illustrate the present invention and, togetherwith the description, further explain the principles of the inventionand enable a person skilled in the pertinent art to make and use theinvention.

FIG. 1 shows a side view of a last according to some embodiments.

FIG. 2 shows a method of manufacturing an article of footwear accordingto some embodiments.

FIG. 3 shows a perspective view of a last with an ankle padding patternaccording to some embodiments.

FIG. 4 shows a side view of a last with an ankle padding pattern andinternal channels according to some embodiments.

FIG. 5 shows a side view of an upper according to some embodiments.

FIG. 6 shows a perspective view of a last with a midfoot support patternaccording to some embodiments.

FIG. 7 shows a side view of a last with a midfoot support pattern and aninternal channel according to some embodiments.

FIG. 8 shows a perspective view of a last with a forefoot patternaccording to some embodiments.

FIG. 9 shows a side view of a last with a forefoot pattern and aninternal channel according to some embodiments.

FIG. 10 shows a side view of a last with internal channels according tosome embodiments.

FIG. 11 shows a side view of a last with a sole pattern and an internalchannel according to some embodiments.

FIG. 12 shows a front view of a last with a sole pattern and an internalchannel according to some embodiments.

FIG. 13 shows a side view of an article of footwear according to someembodiments.

FIG. 14 shows a perspective view of a last with a modular attachmentaccording to some embodiments.

FIG. 15 shows a side view of an article of footwear according to someembodiments.

FIG. 16 shows a side view of an upper according to some embodiments.

DETAILED DESCRIPTION

The present invention will now be described in detail with reference toembodiments thereof as illustrated in the accompanying drawings, inwhich like reference numerals are used to indicate identical orfunctionally similar elements. References to “one embodiment”, “anembodiment”, “an example embodiment”, etc., indicate that the embodimentdescribed may include a particular feature, structure, orcharacteristic, but every embodiment may not necessarily include theparticular feature, structure, or characteristic. Moreover, such phrasesare not necessarily referring to the same embodiment. Further, when aparticular feature, structure, or characteristic is described inconnection with an embodiment, it is submitted that it is within theknowledge of one skilled in the art to affect such feature, structure,or characteristic in connection with other embodiments whether or notexplicitly described.

The term “invention” or “present invention” as used herein is anon-limiting term and is not intended to refer to any single embodimentof the particular invention but encompasses all possible embodiments asdescribed in the application.

The following examples are illustrative, but not limiting, of thepresent invention. Other suitable modifications and adaptations of thevariety of conditions and parameters normally encountered in the field,and which would be apparent to those skilled in the art, are within thespirit and scope of the invention.

Embodiments of the present invention provide footwear with padding andmidsole structures, a method for making the padding and midsolestructures, and a last for making the padding and midsole structures. Insome embodiments, the provided footwear may be athletic shoes. Forexample, the provided footwear may be a running shoe, a soccer shoe, abasketball shoe, a football shoe, a tennis shoe, or any other athleticshoe. In some embodiments, the provided footwear may be a non-athleticshoe.

In some embodiments, a last is provided that defines openings connectedby one or more channels. A polymeric material may be injected throughthe openings and channels to form a structure at various locations on anupper. For example, footwear components may be formed in and around a 3Dupper component, such as a knitted sock. In some embodiments, intricateshapes can be formed inside and/or outside the upper with the use of thelast. In some embodiments, tools external to the last (i.e.,attachments) may help form the footwear components and channel thepolymeric material.

In some embodiments, a last 10, as shown, for example, in FIG. 1, isused to create padding and midsole structures. The structures may beused for comfort, fit, support, haptic feedback, stiffness, flexibility,or other purposes as part of the upper or the sole of an article offootwear. In some embodiments, last 10 includes one or more ports oropenings 12, 13 (see FIG. 3). In some embodiments, opening 12 comprisesan inlet port. In some embodiments, opening 13 comprises an outlet port.In some embodiments, openings 12, 13 are connected by one or morechannels 11 (see FIG. 4) in last 10. In some embodiments, channels 11are disposed in an interior portion of last 10. In some embodiments,channels 11 and openings 12, 13 form a network of passageways throughwhich a material may flow, such as a polymeric material. In someembodiments, one or more channels 11 may intersect such that materialmay flow from one passageway into another passageway.

In some embodiments, a polymeric material is transferred into inletopening 12 through a soft nozzle cover. The soft nozzle cover may bemade of silicone or a similar elastomeric material. In some embodiments,the soft nozzle cover expands within inlet opening 12 to create ahermetic seal between the nozzle and inlet opening 12. In someembodiments, other devices or methods may be used to create a sealbetween the nozzle and inlet opening 12. For example, an O-ring may beused to facilitate a seal between the nozzle and inlet opening 12.

In some embodiments, inlet opening 12 is disposed on a flat surface oflast 10. In some embodiments, inlet opening 12 is disposed on an upperportion of last 10 above the foot form, as shown, for example, in FIG.3. Other placements of inlet opening 12 are also possible. Outletopenings 13 may be disposed in a variety of locations (e.g., anywhere afootwear component is desired to be created). In some embodiments, oneor more outlet openings 13 are disposed on a lateral side of last 10. Insome embodiments, one or more outlet openings 13 are disposed on amedial side of last 10. In some embodiments, one or more outlet openings13 are disposed on a bottom side of last 10. In some embodiments, one ormore outlet openings 13 are disposed on a top side of last 10 (e.g.,over a forefoot). In some embodiments, one or more outlet openings 13are disposed in a heel area of last 10. In some embodiments, one or moreoutlet openings 13 are disposed in a toe area of last 10. A combinationof these positions may also be used. Other placements of outlet openings13 are also possible (e.g., at the vamp, quarters, tongue, etc.).

In some embodiments, inlet opening 12 is disposed at a top of last 10and outlet opening 13 is disposed at a bottom of last 10. In someembodiments, inlet opening 12 is disposed at a bottom of last 10 andoutlet opening 13 is disposed at a top of last 10. In some embodiments,inlet opening 12 or outlet opening 13 is disposed between a top and abottom of last 10.

In some embodiments, the polymeric material comprises a polyurethanefoam. In some embodiments, the polyurethane foam (or other polymericmaterials) may be a single density. In some embodiments, thepolyurethane foam (or other polymeric materials) may be a multi-densitymaterial. In some embodiments, the polymeric material comprisessilicone, urethane, thermoplastic polyurethane, thermoplastic polymer,elastomers, or other liquid plastics. Other materials may also beinjected through channels 11 and openings 12, 13, such as air or othergases. For example, specific additives may be injected with thepolymeric material to speed up or slow down the curing process of thepolymeric material.

In some embodiments, last 10 includes one or more patterns that areembossed on and/or engraved into regions of last 10. The patterns may bedisposed in one or more of the heel region, midfoot region, and forefootregion. The patterns may be disposed on a top, bottom, or side of last10.

In some embodiments, last 10 includes one or more engraved features 14(e.g., a cavity or a recess) on an exterior surface of last 10. In someembodiments, last 10 includes one or more embossed features 15 on anexterior surface of last 10. In some embodiments, engraved features 14and/or embossed features 15 form various patterns on last 10. In someembodiments, engraved features 14 and/or embossed features 15 aredisposed at or near outlet openings 13. In some embodiments, outletopenings 13 are disposed within an engraved feature 14. In someembodiments, outlet openings 13 are surrounded by an embossed feature15. In some embodiments, the ridges or raised structures 45 of embossedfeature 15 (or edges 44 of engraved feature 14) define a closed area andmay help control flashing of the polymeric material when it is injectedthrough channels 11 and outlet openings 13. In some embodiments, theengraved feature 14 and/or the embossed feature 15 define a concavearea, as shown, for example, in FIG. 1.

In some embodiments, engraved features 14 and/or embossed features 15are configured to facilitate forming a footwear component. For example,last 10 in FIG. 1 includes an ankle padding pattern 16 with engravedfeatures 14 and embossed features 15 and a midfoot support pattern 17with engraved features 14 and embossed features 15. In some embodiments,ankle padding pattern 16 is configured to form an ankle padding 36 (seeFIG. 5) with polymeric material that is injected through channels 11 andopening 13. In some embodiments, midfoot support pattern 17 isconfigured to form a midfoot support cage 67 (see FIG. 16) withpolymeric material that is injected through channels 11 and opening 13.

In some embodiments, engraved features 14 are used to form internalpadding and support. In some embodiments, embossed features 15 are usedto form a component that provides haptic texture and/or a 3D design. Insome embodiments, engraved features 14 and/or embossed features 15 areused to form an external component. Patterns on last 10 may be made withonly engraved features 14, only embossed features 15, or a combinationof engraved features 14 and embossed features 15. In some embodiments,edges of embossed features 15 create a seal around a portion of a 3Dfootwear upper component disposed on last 10, preventing the polymericmaterial from seeping outside of engraved features 14 and embossedfeatures 15.

In some embodiments, last 10 may include other patterns instead of or inaddition to ankle padding pattern 16 and midfoot support pattern 17. Inaddition, in some embodiments, different configurations of ankle paddingpattern 16 and/or midfoot support pattern 17 may be used. In someembodiments, last 10 may include embossed and/or engraved patterns inthe toe-box, vamp, quarters, tongue, or other regions of last 10. Asdiscussed in more detail below, last 10 may be configured to provide acustom article of footwear with custom padding and other structures.Thus, a large variety of last configurations and features are possible.

In some embodiments, last 10 is used to make an article of footwear andfootwear components. For example, a method 20 for making an article offootwear is shown in FIG. 2. The operations of method 20 discussed beloware exemplary. In some embodiments, additional operations may be part ofthe method. In some embodiments, not all of the operations shown in FIG.2 are completed. In some embodiments, the order of operations may varyfrom the order shown in FIG. 2.

In some embodiments, at operation 21, data associated with a wearer isobtained. In some embodiments, the data includes the wearer's foot data,performance data, and other data related to creating a customizedarticle of footwear for the wearer. In some embodiments, data may beobtained by performing a foot scan to assess a foot profile for thewearer (e.g., using cameras and/or sensors). In some embodiments, awearer's foot strike profile is measured and analyzed to create an idealprofile for the wearer (e.g., using accelerometers or other sensors).Data may be obtained with other methods. In some embodiments, the datamay be obtained in a retail environment. In some embodiments, data maybe obtained in the manner described in U.S. application Ser. No.15/478,902, filed Apr. 4, 2017 and published as U.S. Publication No.2017/0280828 A1, the disclosure of which is incorporated herein in itsentirety by reference thereto. The data obtained using one or more ofthese methods may be used to customize an article of footwear for aparticular wearer.

In some embodiments, at operation 22, a last (such as last 10) iscreated. In some embodiments, the last's configuration is based on thedata obtained at operation 21. Thus the last may be customized to aparticular wearer. In some embodiments, the last is created based on apredefined digital last, as described in U.S. application Ser. No.15/478,902, filed Apr. 4, 2017 and published as U.S. Publication No.2017/0280828 A1, the disclosure of which is incorporated herein in itsentirety by reference thereto. The predefined digital last may bemodified based on the wearer's foot data.

In some embodiments, the last is created with openings and channels(such as those discussed above for last 10) to form a network ofpassageways through which a polymeric material may be injected. In someembodiments, the last is created with patterns on the last (such asthose discussed above for last 10). In some embodiments, the modifiedlast may be used to determine placement of patterns on the last (such aspadding patterns or support patterns), as well as sole design, for aparticular wearer. The modified last may also be used to determine otherparameters for the patterns on the last, including, for example, thenumber of patterns on the last, the size of patterns on the last, andthe shape of patterns on the last.

In some embodiments, at operation 23, an upper (such as upper 31 (seeFIG. 5)) is created. In some embodiments, the upper is primarily a knitmaterial. In some embodiments, the upper is made of a 3D knit material.In some embodiments, the upper may be made of woven, non-woven, braid,and other forms of textile materials. In some embodiments, the upper maybe made of leather. In some embodiments, the upper's configuration isbased on the data obtained at operation 21. For example, the type ofmaterial, physical properties of the material, and other parameters maybe based on the data obtained at operation 21.

In some embodiments, at operation 24, the upper is positioned on thelast. In some embodiments, the upper is positioned on the last with itsinterior side facing the last. In some embodiments, the upper ispositioned on the last with its exterior side facing the last (i.e.,inside out).

In some embodiments, at operation 25, material is injected through thelast. In some embodiments, the material is a polymeric material. In someembodiments, more than one material is injected through the last, eithersimultaneously or sequentially. In some embodiments, the material isinjected through an inlet opening (e.g., opening 12). In someembodiments, the inlet opening 12 is disposed at a top surface of last10 (see FIG. 3). In some embodiments, the material travels through inletopening 12 into one or more channels 11. Channels 11 may form a networkof passageways and transfer the material to one or more outlet openings13 in various regions of last 10.

In some embodiments, at operation 26, structures (e.g., padding,support, midsole, etc.) are formed on the upper (e.g., upper 31) fromthe polymeric material. In some embodiments, the structures may beformed on an interior side of the upper. In some embodiments, thestructures may be formed on an exterior side of the upper. In someembodiments, the structures, such as an upper padding and a midsole, areformed in a single, continuous process. In some embodiments, thestructures are formed simultaneously. For example, a midsole and anankle padding may be formed simultaneously with a single injection ofpolymeric material. In some embodiments, the structures may be formedsequentially (e.g., ankle padding is formed after the midsole). In someembodiments, the structures are customized based on the data obtained atoperation 21. For example, the location, shape, size, and/or material ofthe structure may be customized.

After the structures are formed, the upper, which now includesadditional structures or footwear components, may be removed from thelast. As noted above, additional operations may be performed. Forexample, in some embodiments, the last may be cleaned after theinjection is complete and the upper is removed.

Examples of various lasts, footwear components, and articles of footwearare shown in FIGS. 3-13. In some embodiments, the features shown in thelasts, footwear components, and articles of footwear of FIGS. 3-13 maybe combined or modified to create other variations of lasts, footwearcomponents, and articles of footwear. For example, ankle padding pattern16 in FIG. 3 and midfoot support pattern 17 in FIG. 6 may be included ona single last. Other combinations and variations are also possible.These variations may depend on the customization for a particularwearer, as noted above.

In some embodiments, a last 10, as shown, for example, in FIGS. 3 and 4,includes an inlet opening 12 and outlet openings 13. Channels 11 connectinlet opening 12 with outlet openings 13. As shown in FIG. 4, channels11 are internal channels (indicated in dotted lines) disposed withinlast 10. In some embodiments, inlet opening 12, outlet openings 13, andchannels 11 form a network of passageways through the last for directingpolymeric material to various locations on the last. In someembodiments, inlet opening 12 is disposed on a top of last 10, forexample, the portion of last 10 associated with an opening in an upperto receive a wearer's foot, as shown in FIG. 3. In some embodiments,last 10 includes a structure 42 surrounding inlet opening 12, as shown,for example, in FIG. 4. Structure 42 may be configured to hold polymericmaterial just before it enters inlet opening 12.

In some embodiments, last 10 includes ankle padding pattern 16. WhileFIG. 3 shows a lateral ankle padding pattern 16 on last 10, last 10 mayadditionally or alternatively include a medial ankle padding pattern 16.In some embodiments, medial ankle padding pattern 16 may be disposedhigher on last 10 than lateral ankle padding pattern 16. In someembodiments, ankle padding pattern 16 includes two outlet openings 13.In some embodiments, last 10 includes a channel 11 extending down frominlet opening 12. In some embodiments, channel 11 breaks into twochannels 11, one for each outlet opening 13. In some embodiments, wherelast 10 includes a medial and a lateral ankle padding pattern 16,channel 11 may break into four channels 11.

Different numbers and configurations of channels 11 are included basedon the number and location of outlet openings 13. In some embodiments,ankle padding pattern 16 includes both engraved features 14 and embossedfeatures 15. In some embodiments, ankle padding pattern 16 is configuredto create ankle padding 36 (see FIG. 5) when polymeric material is movedthrough channels 11 to outlet opening 13.

In some embodiments, last 10 may be used to make upper 31, as shown inFIG. 5. A base layer 32 is placed around last 10. In some embodiments,base layer 32 comprises a textile material, such as a knit or a wovenmaterial. In some embodiments, base layer 32 comprises athree-dimensional knit textile material. In some embodiments, polymericmaterial is moved through channels 11 to outlet opening 13 when baselayer 32 is disposed on last 10. In some embodiments, the polymericmaterial adheres to base layer 32 as it solidifies or cures to formankle padding 36.

In some embodiments, the polymeric material seeps through base layer 32to form ankle padding 36 on an exterior surface of base layer 32. Insome embodiments, the polymeric material forms ankle padding 36 on aninterior surface of base layer 32. In some embodiments, base layer 32may be placed on last 10 inside out so that ankle padding 36 is formedon an exterior surface of base layer 32 without passing through baselayer 32. After ankle padding 36 has been formed, upper 31 (includingbase layer 32 and ankle padding 36) may be removed from last 10.

In some embodiments, a last 10, as shown, for example, in FIGS. 6 and 7,includes an inlet opening 12, an outlet opening 13, and a channel 11connecting inlet opening 12 to outlet opening 13. As shown in FIG. 7,channel 11 is an internal channel (indicated in dotted lines) disposedwithin last 10. In some embodiments, inlet opening 12 is disposed on atop of last 10, for example, the portion of last 10 associated with anopening in an upper to receive a wearer's foot, as shown in FIG. 6. Insome embodiments, last 10 includes a structure 42 surrounding inletopening 12, as shown, for example, in FIG. 7. Structure 42 may beconfigured to hold polymeric material just before it enters inletopening 12.

In some embodiments, last 10 includes midfoot support pattern 17. WhileFIG. 6 shows a lateral midfoot support pattern 17 on last 10, last 10may additionally or alternatively include a medial midfoot supportpattern 17. In some embodiments, midfoot support pattern 17 includes oneoutlet opening 13. In some embodiments, midfoot support pattern 17includes more than one outlet opening 13. In some embodiments, last 10includes channel 11 extending from inlet opening 12 directly to outletopening 13. In some embodiments, where last 10 includes a medial and alateral midfoot support pattern 17, channel 11 may break into twochannels 11, one leading to medial midfoot support pattern 17 and theother leading to the lateral midfoot support pattern 17. In someembodiments, midfoot support pattern 17 includes both engraved features14 and embossed features 15. In some embodiments, midfoot supportpattern 17 is configured to create midfoot support cage 67 (see FIG. 16)when polymeric material is moved through channel 11 to outlet opening13.

In some embodiments, last 10 may be used to make an upper that includesmidfoot support cage 67 in the same manner described above with respectto upper 31 that includes ankle padding 36. Last 10 may also be used tomake an upper with both midfoot support cage 67 and ankle padding 36 (orwith other footwear components).

In some embodiments, a last 10, as shown, for example, in FIGS. 8 and 9,includes an inlet opening 12, outlet openings 13, and a channel 11connecting inlet opening 12 to outlet openings 13. As shown in FIG. 9,channel 11 is an internal channel (indicated in dotted lines) disposedwithin last 10. In some embodiments, inlet opening 12 is disposed on atop of last 10, for example, the portion of last 10 associated with anopening in an upper to receive a wearer's foot, as shown in FIG. 8. Insome embodiments, last 10 includes a structure 42 surrounding inletopening 12, as shown, for example, in FIG. 9. Structure 42 may beconfigured to hold polymeric material just before it enters inletopening 12.

In some embodiments, last 10 includes forefoot pattern 18. Forefootpattern 18 is shown in FIG. 9 as a plan view only for clarity. Forefootpattern 18 is disposed across the top of last 10 in a forefoot region asshown in FIG. 8. In some embodiments, forefoot pattern 18 includes oneoutlet opening 13. In some embodiments, forefoot pattern 18 includesmore than one outlet opening 13, as shown in FIG. 8. In someembodiments, last 10 includes channel 11 extending from inlet opening 12directly to outlet openings 13. In some embodiments, forefoot pattern 18includes both engraved features 14 and embossed features 15. In someembodiments, forefoot pattern 18 is configured to create aproprioceptive feature above the forefoot of the upper when polymericmaterial is moved through channel 11 to outlet opening 13.

In some embodiments, last 10 may be used to make an upper that includesa forefoot proprioceptive feature in the same manner described abovewith respect to upper 31 that includes ankle padding 36. Last 10 mayalso be used to make an upper with both a forefoot proprioceptivefeature and additional components (such as midfoot support cage 67and/or ankle padding 36).

In some embodiments, a last 10, as shown, for example, in FIGS. 10-12,may be used to make a sole 39. Last 10 may include one or more inletopenings 12 and one or more outlet openings 13. In some embodiments,last 10 includes two inlet openings 12, each positioned on a top of last10, for example, the portion of last 10 associated with an opening in anupper to receive a wearer's foot, as shown in FIG. 10. In someembodiments, last 10 includes two outlet openings 13 disposed on abottom portion of last 10. In some embodiments, last 10 includes one ormore channels 11 connecting inlet openings 12 to outlet openings 13. Insome embodiments, last 10 includes two channels 11. As shown in FIG. 10,channels 11 are internal channels (indicated in dotted lines) disposedwithin last 10. In some embodiments, outlet openings 13 are disposedexactly underneath inlet openings 12 so that channels 11 are verticalwhen last 10 is upright.

In some embodiments, sole 39 comprises a midsole. In some embodiments,an upper is formed on last 10 (as described above for upper 31) andwhile the upper is still disposed on last 10, sole 39 may be formed. Insome embodiments, polymeric material seeps through an upper (aftermoving through channels 11) to form sole 39.

In some embodiments, as shown in FIGS. 11 and 12, last 10 includes asole pattern 19. In some embodiments, sole pattern 19 is disposed in abottom portion of last 10. In some embodiments, sole pattern 19comprises a cavity that extends most of the length of last 10 and mostof the width of last 10. In some embodiments, sole pattern 19 may beused to form an insole. A base layer may be placed around last 10 (asdiscussed above with respect to upper 31). Then polymeric material maybe moved through one or more channels 11 to fill in sole pattern 19 onan interior side of the base layer. As shown in FIGS. 11 and 12, channel11 is an internal channel (indicated in dotted lines) disposed withinlast 10. The resulting upper with an embedded insole may be removed forincorporation into an article of footwear.

An article of footwear 30 made with last 10 (as described above) isshown, for example, in FIG. 13. Article of footwear 30 includes upper 31and sole 39. In some embodiments, upper 31 includes base layer 32 andone or more footwear components. The footwear components may be internalor external components, including the components described above, aswell as other components made with the methods described above. Forexample, in FIG. 13, upper 31 includes an internal ankle padding 36. Insome embodiments, ankle padding 36 and midsole 39 are formed with asingle injection of polymeric material through last 10. Thus, anklepadding 36 and sole 39 may be a single-injection midsole and paddingdisposed on upper 31. The single-injection midsole and padding may bedistinct from upper 31.

In some embodiments, to help form the footwear components with thepolymeric material injected through last 10, modular attachments areused. For example, as shown in FIG. 14, modular attachment 40 may helpform ankle padding 36 with ankle padding pattern 16. In someembodiments, modular attachment 40 interfaces with an outer surface oflast 10. For example, an inner surface of modular attachment 40 maycorrespond in shape to an outer surface of last 10. In some embodiments,base layer 32 is disposed between last 10 and modular attachment 40. Insome embodiments, modular attachment 40 helps prevent polymeric materialfrom seeping through base layer 32 to better form an interior footwearcomponent.

Modular attachments may be various shapes and sizes to allow for greatercustomization to a particular wearer. The shape and size of modularattachments may depend on the location of the footwear component beingcreated. The modular attachments may be used to adjust the level ofpadding for a particular footwear component.

In some embodiments, modular attachment 40 may include features (e.g.,cavities or recesses) on its interior surface. In some embodiments, thisconfiguration facilitates forming external footwear components. Forexample, the polymeric material may seep through base layer 32 and fillin the cavity or recess on modular attachment 40. The shape of thecavity or recess shapes the external footwear component into the desiredshape.

In some embodiments, multiple modular attachments 40 are used. Forexample, two modular attachments 40 may attach to each other to surroundlast 10 during the injection process to help form footwear components.In some embodiments, a modular attachment may be disposed between last10 and base layer 32.

In some embodiments, modular attachments are used to divert and/orchannel polymeric material to and from desired regions on last 10. Insome embodiments, modular attachment 40 may include channels. Forexample, polymeric material may be injected through modular attachment40 to form footwear components.

In some embodiments, an article of footwear 50 may be made with a sole52 having dual density, as shown, for example, in FIG. 15. For example,sole 52 may be made up of a first density material 53 and a seconddensity material 54. In some embodiments, first density material 53 andsecond density material 54 are injected through last 10 sequentially (ineither order). In some embodiments, first density material 53 and seconddensity material 54 are injected simultaneously.

In some embodiments, the configuration of the last 10 facilitates a dualdensity sole 52. For example, last 10 may include a first opening with achannel directed to an outlet in the heel portion of the last and asecond opening with a channel directed to an outlet in the forefootportion of the last. Different materials may be directed through eachchannel to form a dual density sole 52. In some embodiments, differentmaterials may be directed through a single channel to form a dualdensity sole 52.

Creating a dual density sole 52 (or a sole with more than dual density)facilitates customization of article of footwear 50 to a particularwearer.

In some embodiments, other components may be made of more than onematerial, as shown, for example, in FIG. 16. In some embodiments, anupper 61 includes a heel component 65, toe component 66, and midfootsupport cage 67. Heel component 65, toe component 66, and midfootsupport cage 67 may each be formed with material injected through last10, as described above with respect to other components. In someembodiments, heel component 65, toe component 66, and midfoot supportcage 67 each have dual density. For example, heel component 65, toecomponent 66, and midfoot support cage 67 may be made up of a firstdensity material 62 and a second density material 63. In someembodiments, first density material 62 and second density material 63are injected through last 10 sequentially (in either order). In someembodiments, first density material 62 and second density material 63are injected simultaneously.

Various embodiments described herein provide improved footwearmanufacturing that allows for shaping footwear components in anefficient, customizable, and fast manner. Internal and/or externalfootwear components for comfort, support, fit, stiffness, flexibility,and/or haptic feedback may be created directly on an upper. Thesecomponents may be precisely formed in a customized manner by injecting amaterial through a last having an internal network of passageways (e.g.,inlets, channels, and outlets) to various areas of the upper. The lastmay include engraved and/or embossed features on its outer surface toform the footwear components. In some embodiments, modular attachmentsmay be used to assist in the formation of the footwear components. Othervariations are also possible. For example, instead of a last, a similarfoot form or shaping tool may be utilized to form footwear components ina similar manner.

In a further embodiment, a method of manufacturing an article offootwear, the method comprising positioning an upper on a last, the lastdefining openings connected by one or more channels in the last,injecting a material through the one or more channels in the last, andforming a structure on the upper with the material.

In a further embodiment, the structure comprises a midsole.

In a further embodiment, the structure comprises upper padding.

In a further embodiment, the openings comprise an inlet at a top of thelast and an outlet at a bottom of the last.

In a further embodiment, the method further comprising customizing thestructure based on data associated with a wearer.

In a further embodiment, the last defines a cavity at a bottom portionof the last.

In a further embodiment, the cavity extends most of the length of thelast and most of the width of the last.

In a further embodiment, forming the structure on the upper comprisesforming an insole in the cavity.

In a further embodiment, the last comprises a pattern with at least oneof engraved features and embossed features.

In a further embodiment, a method of manufacturing an article offootwear, the method comprising positioning an upper on a last,injecting a material through the last, and forming upper padding and amidsole with the material in a single, continuous process.

In a further embodiment, the method further comprising injecting asecond material through the last.

In a further embodiment, the method further comprising using a modularattachment to shape the upper padding.

In a further embodiment, the method further comprising obtaining footdata associated with a wearer.

In a further embodiment, the method further comprising using the footdata associated with the wearer to customize the midsole and the upperpadding.

In a further embodiment, an article of footwear comprising an upper anda single-injection midsole and padding disposed on the upper, whereinthe single-injection midsole and padding is distinct from the upper.

In a further embodiment, the padding is disposed on an outside of theupper.

In a further embodiment, the padding is disposed on an inside of theupper.

In a further embodiment, the padding is customized based on foot dataassociated with a wearer.

In a further embodiment, the midsole comprises multiple materials.

In a further embodiment, the midsole comprises a multi-density material.

The foregoing description of the specific embodiments will so fullyreveal the general nature of the invention that others can, by applyingknowledge within the skill of the art, readily modify and/or adapt forvarious applications such specific embodiments, without undueexperimentation, without departing from the general concept of thepresent invention. Therefore, such adaptations and modifications areintended to be within the meaning and range of equivalents of thedisclosed embodiments, based on the teaching and guidance presentedherein. It is to be understood that the phraseology or terminologyherein is for the purpose of description and not of limitation, suchthat the terminology or phraseology of the present specification is tobe interpreted by the skilled artisan in light of the teachings andguidance.

The breadth and scope of the present invention should not be limited byany of the above-described exemplary embodiments, but should be definedonly in accordance with the following claims and their equivalents.

What is claimed is:
 1. An article of footwear comprising: an upper; anda single-injection midsole and padding disposed on the upper, whereinthe single-injection midsole and padding is distinct from the upper. 2.The article of footwear of claim 1, wherein the padding is disposed onan outside of the upper.
 3. The article of footwear of claim 1, whereinthe padding is disposed on an inside of the upper.
 4. The article offootwear of claim 1, wherein the padding is customized based on footdata associated with a wearer.
 5. The article of footwear of claim 1,wherein the midsole comprises multiple materials.
 6. The article offootwear of claim 1, wherein the midsole comprises a multi-densitymaterial.